Operating Experience in the USA 

ecent Coal Fired SCR Operating Experience in the USA 

Presented to 

2001 EPRI SCR Workshop 

 Thanks to: AES, B&W, CP&L, FW 

P&L John Calvello 

Hitachi America, Ltd. 

HITACHI i 

lnspire the Ne,cl ~E' 
Recent Coal Fired SCR Operating F.xperience in the USA 

 SCR System Application and Experience 

Fired Boiler 

• BOILER • FURNACE • COKES OVEN 

---· 

HITACHI 1 

lnspire the Ne,c\: 12E 

26-3 
Operating Experience in the USA 

t Coal Fired SCR Systems Currently Operating with 

hi Plate Type Catalyst in the USA 

-AES, Somerset, July 1999 

- Bituminous Coal- Medium-High Sulfur - High Dust, PC Fired 

- Cleaning via Steam Sootblowing 

-CP&L Roxboro #4, July 2001 

- Bituminous Coal- Low Sulfur - Low Dust, PC Fired 

- Cleaning via Acoustic Horns 

-KCP&L Hawthorn, May 2001 

-Sub-Bituminous Coal (PRB) 

-High Dust, PC Fired 

-Cleaning via Acoustic Horns 

HITACHI l 

Inspire the Nexl 
Recent Coal Fired SCR Operating Experience in the USA 

ne of Hitachi 6.0 mm Plate Type Catalyst 

ALYST ELEMENT 

ss: Approx. 0.9mm) 

CATALYST UNIT 

(Size: Approx. 500 x 500 x 500 (mm)) 

·---·--· ···- ---·-··------------------

CATALYST BLOCK 

HITACHI 1 

lnspire the Nexl ,4E 

26-5 
Operating Experience in the USA 

Somerset - 675 MW SCA 

Project Completed in 1999 

) 

Supplied Courtesy of Babcock & Wilcox i 

HITACHI I. 

lnspire the Nex\: lsE1 
ES Somerset 

75 MW SCR System 

Air Heater 

Existing 

Structural Steel --

-·-···-·----

Recent Coal Fired SCR Operating Experience in the USA 

Damper SCR Ammonia Seal Air 

Bypass Injection System Piping 

t 

From Ammonia 

Storage System 

SCR 

Reactor 

Catalyst 

Layer 

--ti---- Future 

Future 

Cataly,it . 

... To Precipitator 

New Structural Steel 

HITACHI , lnspire the Next 1iiE 

26-7 
Operating Experience in the USA 

Somerset Coal Analysis 

Coal data for AES/Somerset 

Heat 

Moist 

Vol 

FC 

Ash 

s 

C 

H 

N 

0 

Cl 

Si02 

Al203 

Fe203 

Ti02 

P205 

Cao 

MgO 

Na20 

K20 

S03 

As 

Ba 

Mn 

-------

BTU/Lb 

(%) (%) (%) 

(%) (%) (%) (%) (%) 

(%) (%) (%) (%) (%) (%) (%) 

(%) 

(%) (%) (%) 

(%) 

PPM 

PPM 

PPM 

Average Max Min 

13023 13237 12550 

5.87 6.18 5.53 

37.05 40.09 35.6 

49.49 52.03 44.79 

7.88 9.15 6.67 

2.41 4.12 1.41 

71.90 74.36 68.41 

4.90 5.21 4.69 

1.31 1.53 1.14 

6.47 7.2 5.63 

0.12 0.14 0.07 

46.44 51.3 42.81 

22.31 26.18 19.28 

18.26 28.79 12.6 

0.96 1.17 0.87 

0.28 0.44 0.04 

4.20 5.92 2.61 

0.84 0.98 0.67 

0.53 0.7 0.42 

1.37 1.49 1.2 

4.96 7.18 3.05 

4.44 6.73 2.77 

5.93 10.95 0.2 

15.59 21 .05 10.92 

HITACHI : 

1nspire the Next 
 Somerset Catalyst Design Parameters 

uration 

tion 

ercial Operation 

low 

emp 

nlet 

Outlet 

x Efficiency 

st Volume 

elocity 

o S03 Conv 

ure Drop 

st Life 

·-----

675MW 

Bit Coal 

High Dust 

Ozone Season 

July 1999 

6,500,000 lbs/hr 

649 F 

340 ppm 3% 

7% 

1140-3490 ppm 

5 gr/dscf 

34 ppm 90% 3 ppm 

897m3 

6.0 mis 

<0.75% 

2.8 inwg 

24,000 hr 

Recent Coal Fired SCR Operating Experience in the USA 

HITACHI r 

lnspiTe the Nex~ !se 

26-9 
 Operating Experience in the USA 

Somerset Catalyst Cleaning 

eam Sootblowers provided for on line cleaning 

Operated Once per Week 

Catalyst Remains Clean 

No Increase in Pressure Drop Observed 

 manual cleaning has been required at any time 

 build up of ash on catalyst has been observed 

-----

HITACHI i 

Inspire the Next tsE 
Recent Coal Fired SCR Operating Experience in the USA 

 Somerset Catalyst 

Somerset Catalyst after 2 ozone seasons of operation. 

Max. design gas velocity at catalyst face is 23.6 ft/s (6.0m/s). 

HITACHI I 

lnspire the Next IO 

26-11 
 Operating Experience in the USA 

Somerset Catalyst 

 erosion and no dust plugging has been observed. 

HITACHI 1 

Inspire the Nexl !1 
Recent Coal Fired SCR Operating Experience in the USA 

S Somerset Catalyst Deactivation - Expected vs Actual 

I-Design(Expected) • Somerset I 

1.2 

1 

0.8 

0.6 

0.4 

0.2 

0 

I 

········ ... 

···-:··················· 

···················· .... ., ............... , 

- l KO=Design Initial Activity I 

0 5000 10000 15000 20000 25000 30000 

Operating Time (h) 

HITACHI i 

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26-13 
 Operating Experience in the USA 

L Roxboro #4 SCR Reactor 

Operation: July 2001 

-

~~~~====:::::: 

HITACHI l 

Inspire the Nex\: 131 
Recent Coal Fired SCR Operating Experience in the USA 

L Roxboro #4 - Arrangement of Flues & SCR 

~__.---------fl-

[l .af~]'.' ___ 

its h ,a,:-~! 

(JaSTIHCrtUCPlrCOPIT•IOII\ 

,, ...... .,,.,T-~ 

I 

~---------------------

! ·-.... ....-· 

t .......... • /". 

I ....._ _,.-

1 ......... _ .......... 

I _,.- ....._ 

I _,.- ....._ 

I 

_ _.,,- .......... 

---

V V V V 

HITACHI 

Inspire the N exl: ~4 

26-15 
 Operating &perience in the USA 

L Roxboro #4 Arrangement of Flues & SCR 

r=r-· 11·---~ ff·--T,---11 

1i i I I ii11i i i i ii1 1··1 

IU_ I I _JJI '!ILL' I I i ii '~-:-~~, __ 

~

-gS_ ~--~-- . . ,,~-----==h4- I ', i ~/ 

~ - ' .. 2 : . '~------~:1' "/ .;.:i~ ' : /::::,::::.,_ 

. ' ' .. ', ' ',, /:: ... , ~-::: _____ [_ ___ ::-~- 'v:' V .-. . . -- c,--------,----,--- ._ 

- --- - - - - --- - - - - --- - - ----

, ,' ·-;_: : ... - - ---~~··-f .. :r,_f'.'.'.: .f''" 

= == ==== = cc===-==f3 ::::::::'. • · :,1 I j I I 

, , r~ D ~-- * --.__,,1·: :""- ... -----~i- -i--+---i - J 

_ __ _j__j __ ~ _,_ c _ ·1: -_<>.~j : '~!ff !¥i i j 

ij~.:~~- ~ I 1'·· ::~ ·1 . ;--.:. .~.:··:--···--:--'!l-------1 I'---+ I I I Ii . , ________ i _______ _ ----- ----. ---. -----' -'--- . ,i · 'I '-.'·-- : .. : i 

-E----- --=i-1=--- -!---- 1 - 1 1, ·--- :" : i ----- --- ,··: -----, -,--- : 'i .. U : I ~:.l\·:~::l\:·7 ,::l\::~---_l\·_:=;Ji' ·v v· v:·v· v· 

v,' v,' ·.v: -.v: -.v: '-v,' ·v: -.v:

1 1 

-------·----

HITACHI 1 

lnspire the Nexl isi 
Recent Coal Fired SCR Operating Experience in the USA 

L Roxboro #4 - Arrangement of Flues & SCR 

t·-

---·-·-----·-·_..._.___ __ I ________ _ 

I 

D D D 

a a 

D D 

s======s> 

FF v ul ID a 

D D D 

rP-.. r"--, .. _,,, 

~--~ ~--~ 

i i 

L .. J 

1!:'~J~9~!~ ~6 

26-17 
 Operating Experience in the USA 

L Roxboro #4 Coal Analysis 

Coal data for Roxboro #4 

Heat 

Moist 

Vol 

FC 

Ash 

s 

C 

H 

N 

0 

Cl 

Si02 

Al20 3 

Fe20 3 

Ti02 

P20 5 

Cao 

MqO 

Na20 

K20 

S03 

As 

Be 

Mn 

Max 

BTU /Lb 13 ,500 

(%) 3 (%) 28 (%) 45 (%) 5 (%) 1 .5 (%) 80 

(%) 6 (%) 1 . 7 (%) 8 (%) 0 . 1 (%) 70 

(%) 38 (%) 25 (%) 3 .5 (%) 0 .6 (%) 10 (%) 8 (%) 4 .0 (%) 3 .0 

(%) 1 0 

PPM 12 

PPM 3 PPM 78 

Min 

10 ,500 

11 

39 55 

1 7 

0 .4 

60 

4 

1 .0 

2 

0 .01 

1 0 

8 

2 

0.4 

0 . 1 

0.5 0.3 

0 .1 

0. 1 

0 . 1 

0 

0 0 

HITACHI i 

lnspire the Nexl 
Recent Coal Fired SCR Operating F.xperience in the USA 

L Roxboro #4 - Catalyst Design Parameters 

e 735MW 

el Bit Coal 

nfiguration Low Dust 

eration Ozone Season 

mmercial Operation July 2001 

s Flow 1,206,000 Nm3/hr / 1,725,300 ACFM 

s Temp 735 F 

x Inlet 278 ppm 

 3.25% 

0 6.5% 

2 630 ppm 

st 100 mg/Nm3 

x Outlet 58.5 ppm 

NOx Efficiency 79% 

p 2 ppm 

alyst Volume 314.8 m3 

s Velocity 6.0 mis 

2 to S03 Conv <1.0% 

ssure Drop 1 .3 inwg (33 mm H20) 

alyst Life 24,000 hr 

-----------

. 

HITACHI 

lnspiTe the Ne"\: as: 

26-19 
Operating Experience in the USA 

oro 4 Hitachi Catalyst 

-------------------------------------1 

HITACHI i 

Inspire the Ne>ct: ~91 
L Roxboro #4 Catalyst Cleaning 

ow Dust SCR system 

HA Acoustic Horns Utilized for on line cleaning 

 Eight Horns Per Reactor  4 Sonic Horns are located above each catalyst layer  No increase of SCR pressure drop has been observed 

o manual cleaning is anticipated 

------

Recent Coal Fired SCR Operating Experience in the USA 

HITACHI ( l nspire the Ne,cl 

26-21 
Operating Experience in the USA 

ustic Horns - Roxboro 4 

HITACHI I 

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Recent Coal Fired SCR Operating Experience in the USA 

L Roxboro #4 Performance Test Results 

erformance Test Results 

 Design NOx Removal of 79% has been achieved: 

Minimum Load Ammonia Slip: 0.1 ppm 

Full Load Ammonia Slip:: 0.4 ppm 

 S02 to S03 Oxidation Rate 

<1 % has been demonstrated 

 Pressure Drop 

Data Unavailable 

HITACHI : 

lnspire the Next 

26-23 
Operating E.xperience in the USA 

KCP&L's Hawthorn Unit 5 - June 2001 

HITACHI l 

lnspire the Ne" t 
thorn Unit 5 S de View 

'1 i I I I I ' I I 

I 

-- -------- ·- --

Recent Coal Fired SCR Operating Experience in the USA 

•4,000,000 lb/hr 

•2600 psi, 1005F/1005F 

•(2520, 1000F/1000F@ turbine) 

HITACHI ( lnspire the Next i4 

26-25 
 Operating Experience in the USA 

&L Hawthorn Coal Analysis 

Coal data for Hawthorn 

-

Heat 

Moist 

Vol 

FC 

Ash 

s 

C 

H 

N 

0 

Cl 

Si02 

Al203 

Fe203 

Ti02 

P205 

cao 

MqO 

Na20 

K20 

S03 

As 

Bao 

Mn 

BTU/Lb 

(%) (%) 

(%) (%) (%) 

(%) (%) 

(%) 

(%) (%) (%) 

(%) (%) (%) 

(%) 

(%) 

(%) (%) (%) 

(%) 

PPM 

PPM PPM 

Average Min 

8350 8100 

30 .6 29.0 

31 .1 28.8 

32 .8 30.5 

5.5 4.6 

0.33 0.23 

48 .0 46.3 

3.4 3.1 

0.70 0.6 

11 .5 -

0.01 0.00 

33.0 27.9 

15.5 13.2 

6.0 3.6 

1.3 0.8 

1.7 1.0 

22.5 17.6 

4.0 1. 7 

1.4 0.4 

0.3 0.0 

13.0 10.1 

- -

- -

- -

Max 

8600 

32 .2 

33.4 

35.9 

6.4 

0.43 

49.6 

3.7 

0.8 

-

0.02 38.1 

17.8 

8.4 

. 1.8 

2.4 

27.4 

6.3 

2.4 

0.6 

15.9 

-

-

-

HITACHI l 

Inspire the Next: 
&L Hawthorn - SCR Design Parameters 

e 

el 

nfiguration 

eration 

mmercial Operation 

s Flow 

s Temp 

x Inlet 

 

0 

2 

st 

x Outlet 

NOx Efficiency 

p 

alyst Volume 

s Velocity 

2 to S03 Conv 

ssure Drop 

alyst Life 

500MW 

Sub Bit Coal 

High Dust 

Continuous 

May 2001 

5,595,000 lbs/hr 

695 F 

135 ppm 

3.5% 

13.6% 

420 ppm 

32710 lbs/hr 

59.2 ppm 

55.6% 

2 ppm 

477 m3 

5.7 mis 

<0.75% 

2.0 inwg 24,000 hr 

Recent Coal Fired SCR Operating Experience in the USA 

HITACHI . 

l nspiTe the Next 26 

26-27 
Operating Experience in the USA 

&L Hawthorn - Catalyst Cleaning 

gh Dust SCA system 

PC Fired (High Ash Loading) 

A Acoustic Horns Utilized for on line cleaning 

Eight Horns Per Reactor 

4 Sonic Horns are located above each catalyst layer 

Catalyst has remained very clean 

No increase of SCR pressure drop has been observed 

 manual cleaning is anticipated 

HITACHI \ 

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oustic Horns - KCP&L Hawthorn 

Recent Coal Fired SCR Operating Experience in the USA 

Supplied Courtesy of B&W and KCP&Lx ! 

HITACHI I 

lnspire the N ext~, 

26-29 
Operating Experience in the USA 

&L Hawthorn - Catalyst Performance 

A Tuning is Currently On-going 

eliminary Data Indicates Guaranteed Performance is being Achieved 

==-----

H ITACHI I 

lnspire the N ex\: !191 
Recent Coal Fired SCR Operating Experience in the USA 

chi Catalyst Formulations for Coal Fired Applications 

our Basic Formulations Offered 

 C3, C2, C1 , and CO 

3 Catalyst 

 Most Reactive Catalyst 

 Lowest Catalyst Volume  Highest S02 to S03 Oxidation Rate 

 Works well at relatively Low Temperature 

2 and C 1 Catalyst 

 Less Reactive than C3  Lower S02 to S03 Oxidation Rate than C3 catalyst 

 Works well at Medium Temperatures 

O Catalyst 

 Very Reactive at High Temperature  Reactive Drops off Quickly with Lowering Temperatures  Lowest S02 to S03 Oxidation Rate 

 Works well at relatively High Temperatures 

HITACHI I 

lnspire t h e N ex\: ~ 1 

26-3 1 
Operating Experience in the USA 

 Study - Comparison of Hitachi Catalyst Formulations 

% NOx Removal, 2 ppm Slip, 16,000 hours life 

Temperature C3 C2 

Catalyst Catalyst 

Case 1 

Volume 700F X ax 

02 -> S03 1.2 1.0 

Case 2 

Volume 750F - -

2 -> S03 - -

Case 3 

Volume 780F - -

2 -> S03 - -

 1 : a < < y '

-------

Note 2: 8 < 1 Note 3: £ < 1 

C1 co 

Catalyst Catalyst 

~x yx 

0.6 0.5 

y 8y 

1.0 0.5 

z cZ 

1.4 0.5 

HITACHI I 

Inspire the Next ~ 
Recent Coal Fired SCR Operating Experience in the USA 

clusions 

S Experience with Hitachi Plate Type Catalyst is Excellent 

 SCR Configurations 

High Dust 

Low Dust 

 Fuels 

Bituminous Coal 

Sub-bituminous Coal (PRB) 

 Sulfur 

High Sulfur 

Low Sulfur 

 Catalyst Stays Clean 

Sootblowers Sonic Horns 

 S02 to S03 Oxidation Rate 

Tailored to Requirements 

- --------- ·----------···---·-·•-••·----·•-••P•q---~---------------

HITACHI I 

lnspiTe the Next~ 

26-33